Molded pulp carton



May 4, 1954 H. s. CRANE MOLDED PULP cmoN 2 Sheets-Sheet 1 Filed July 25, 1948 INVENTOR. fibroid? Craize,

May 4, 1954 H. s. CRANE MOLDED PULP CARTON 2 Sheets-Sheet 2 Filed July 25, 1948 Jilllll'ilil'llllfllI1 IN VEN TOR. fizz/"012i JC/ru'ze,

Patented May 4, 1954 MOLDED PULP CARTON Harold S. Crane, Palmer, Mass., asslgnor to Shellmar Products Corporation, Chicago, 111., a corporation of Delaware Application July 23, 1948, Serial No. 40,358

13 Claims. 1

This invention relates to improvements in molded pulp cartons of the type which are particularly adapted for use in packaging eggs or other articles of a similar nature.

It is an object of the invention to provide acellular carton of the type which may be molded from a watery slurry of paper pulp fibers and which is characterized by a body portion having a plurality of upwardly opening cells for receiving eggs or similar article and hingedly connected side wall and top forming portions which are adapted when closed to form with the body portion a container of generally rectangular cross section.

It is a more specific object of the invention to provide a cellular carton adapted to be molded from a watery slurry of paper pulp fibers which comprises in the open position in which it is removed from the mold a central bottom forming portion having a plurality of upwardly opening ovoid cells and integral side wall and cover forming portions on the opposite sides of the bottom forming portion having the side wall and cover sections thereof extending in upwardly diverging angular relation to each other.

It i another object of the invention to provide a molded pulp carton of the type described which includes a central bottom forming portion having end wall formations terminating at the top in abutment formin edges which extend downwardly and outwardly in diverging relation and side portions on opposite sides of the central portion having angularly related side wall and cover forming sections which are connected at their ends by generally triangular shaped end walls the upper edge of which extends upwardly and outwardly relative to the abutment edges of the bottom end walls.

It is a further object of the invention to provide a cellular molded pulp carton of the type described wherein the central bottom forming portion is provided with a plurality of cell formations separated by a medial row of upwardly extending pyramidal partition members which terminate in top abutments and wherein the side wall and cover forming portions which are hingedly connected along opposite sides of the bottom forming portion are provided with partition forming flaps on their outer edges which ar adapted to be folded into downward juxtaposed relationship in the closed position to bring them into edge abutting relation with the tops of the pyramidal partition members.

It is another object of the invention to provide a molded pulp carton of the type described wherein elements are provided which are adapted to be arranged in interengaging relation for securing the cover members in the closed position.

It is a further object of the invention to provide a cellular molded pulp carton of the type described wherein locking apertures are provided in the end walls of the bottom portion and cooperating locking tongues are provided on the end walls of the side wall and cover portions for engagement in the apertures.

It is a still further object of the invention to provide a cellular eg carton which is particularly adapted for accommodating large eggs while still being capable of being packed in a standard egg crate and which affords increased protection for the eggs packed in the carton.

These and other objects of the invention will be apparent from a consideration of the cartons which are shown by way of illustration in the accompanying drawings, wherein:

Fig. 1 is a molded pulp carton which incorporates therein the principles of the invention, the carton being shown in the open position in which it is removed from the mold;

Fig. 2 is a cross section taken on the line 2-2 of Fig. 1;

Fig. 3 is a top plan view of the carton with the side wall and cover members in the closed position;

Fig. 4 is an end elevation to an enlarged scale of the carton in the closed position;

Fig. 5 is a partial longitudinal section taken on the line 5-5 of Fig. 4;

Fig. 6 is a transverse section to an enlarged scale taken on the line 6-S of Fig. 3;

Fig. 7 is a transverse section to an enlarged scale taken on the line l-| of Fig. 3;

Fig. 8' is an end elevation similar to Fig.- 4 showin a modified form of the carton; and

Fig. 9 is a partial transverse section similar to Fig. 7 showing a further modified form of the carton.

In order to provide a carton which is capable of being molded in the usual manner from a watery slurry of paper pulp fibers, it is necessary to design the carton without any overhanging or downwardly flaring portions so that it may be readily removed from the mold after it has been formed without any damage to the carton members. The surfaces of all recessed portions of the carton must be tapered or curved upwardly and. outwardly to facilitate removal from the mold member. Where there are apertures or lines of weakening to be formed in the carton they must be designed so that the projecting mold members which form the same are provided with a taper or curvature which will permit unobstructed removal of the carton from the mold. These limitations on the design of molded articles have made it difiicult to produce a satisfactory molded pulp carton having straight or vertical side walls.

Referrin to Figs. 1 to 7 of the drawings, there is illustrated a carton which is generally rectangular in cross section when in closed condi- The carton comprises, in the opened out or unfolded condition in which it is molded, a central body forming portion Iii andside wall and cover portions H and I2 which are integrally connected along opposite sides of the body forming portion [0.

The body portion ID of the carton is provided,

with two longitudinally extending rows of six pocket forming recesses or cell formations 13, which are adapted toaceommodate a dozen eggs. The cell-forming recesses L; are generally semicircular or ovoid and open upwardly and inwardly, being arranged in transversely aligned pairs. The downwardly projecting bottom wall portions i l of the cells 13 constitute the bottom of the carton. The outer wall portions of the pair of cells 13 at each end of the carton form carton end walls 15 which terminate at the-top in abutment forming edges it which extend outwardly and downwardly from the longitudinal center of the carton in diverging relation. The walls of adjacent cells i3merge with each other and form relatively shallow transverse and longitudinally extending vertical partition members ill and 28, respectively. The partition. forming walls of adjacent pairs of cells. l3 also merge to form central upstanding pyramidal partition members 59 whichv provide a row of top abutments 29 spaced along a longitudinal medial line. The longitudinal partition members 18 extend between the pyramidal abutment forming, members is con necting the same along the medial line. The transverse partition members F extend from the pyramidal members l9 toward opposite side edges of the bottom forming portion lb of the carton. Each of the end walls 15 is provided with a central locking aperture 2| which is spaced from the top edge It and extends downwardly and into the end longitudinal partition member H3.

The side wall and cover forming portions H and i2 extend on opposite sides of the bottom portion H! of the carton. Preformed hinge lines 22 and 23 define the connecting, edges of the respective side portions. ll and i2 and the bottom portion Ill. The side portions H and i2 are provided, with identical side wall panels or members 24. and. 25,. respectively, and cover panels or members 26 and 21', respectively. The side walls 2'4. and extend downwardly and outwardly from the bottom portion I8 and are in substantially right-angled relationship with the cover members 26 and 21, respectively.

At the ends members 24 and 25 are connected by generally triangular shaped end walls 28 while members 26 and 21 are connected by similar end walls 29. The end walls 28 are, connected along two right-angled edges 30 and 3|. to the side wall 24 and cover member 26", respectively. The outer edge 32 of the end wall 28 extends from the end of the top edge H; of the end wall l5 in an outward and upward direction when the carton is in the opened out condition. The end walls 29 are connected along the right-angled side edges 33 and 34 to the ends of the side wall 25 and cover member 21, respectively. The outer edge 35 extends outwardly and upwardly from the end of the toped'ge iii of the endwall l5 on the opposite side of the bottom I0. I

' The cover members 26 and slope outwardly 4 and upwardly and are provided along their outer margins with partition forming portions or fiap members 36 and 3! whichv are separated therefrom by preformed hinge lines 38 and 39. The partition forming flap members 36 and 3'! are not connected at their ends to the end walls 28 and 2%), respectively, and are free to hinge along the lines 38 and ac. to form a medial partition when the carton members are in closed condition. The outer edge of the partition forming flap 38 is relieved by spaced semi-circular recesses 40 which are separated by abutment ion. ing edge portions 4| which are adapted to rest on the top abutment surfaces 28 of the pyramidal partition members i9 when the carton is closed. The partition forming flap 31 has a straighter plain outer edge which is adapted to rest on the surfaces 2% in the closed position.

The end walls 23 and 29 are not connected to the ends of the partition flaps 35 and 31 but terminate in relatively short downwardly extending edges 42 and 43, respectively, which define one side of generally V-shaped slots 4-. and c5 separating the end walls from the flaps 36 and 3?. Adjacent the outer ends of the end walls 28 and 22 there are provided integral longitudinally extending locking tabs 4% and 41, respectively. The locking tabs 45 and 4'! each comprise a base portion 48 and a head portion 49 with a section of reduced width separating the same.

When the side wall and cover forming portions ii and 22 of the carton are hinged about the lines 22 and 23 to the closed position the outer portions of the end walls 28 and 28 overlap (Fig. 4) at the ends of the carton and the locking tabs 48 and 41 carried thereon are brought into superimposed relation so that the head portions d9 thereof may be forced through the aperture 2! in the bottom end wall I5, and into interlocking engagement therein, the head portions 49 of the tabs moving into the space between the eggs in the adjacent pair of cells at the end of the carton.

As previously described, the partition forming flaps 35 and 31 are adaptedv to extend downwardly in a generally vertical plane when the carton is in the closed position (Fig. 6) and to engage in abutting relation with the free edges thereof abutting the tops 29 of the pyramidal members i5. The partition members 36 and 3? are adapted to be held in such position by engagement of the locking tabs 46 and 41'. in the apertures 2| in the end walls l5. Additional locking means are preferably provided in connection with cover members 26 and 21.

The cover members 25 and 2'! are provided with generally semi-circular apertures 53 which are spaced some distance from each end adjacent the hinge lines 38 and 39. The apertures at corresponding ends of the carton are in transverse alignment in the closed position of the cover members. The apertures 50 are shaped so that tab portions 5| are formed on the partition flaps 3i": and 31' which extend upwardly slightly above the top surface and in abutting relation in the closed position. The tab portions 5lmay be secured together by conventional fastening means such as staples 52-. The apertures 50 and the tabs 5| are preferably aligned with the cross partition formation 11 between the two end pairs of cells l3'so that the stapling operation does not result in egg breakage, the staple 5-2 being insertedin the; space between the upwardly projecting portions of the eggs in these cells. The apertures 50 also permit observation of the con tents of the two end pairs of cells 13 when the carton is closed.

The cover members 28 and 21 may also be provided with cooperating locking members 53 and 54 which are arranged in alignment with the cross partition formation ll between the second and third pairs of cells from each end of the carton. The 1ocking members 53 and 54 are provided by generally horseshoe-shaped weakening lines 55 and 56 extending away from the hinge lines 38 and 38. The one looking member 54 is made somewhat shorter than the other member 53 so that the fingernail may be inserted beneath the member 54 in a space 51 and the member 54 may be torn loose along the weakened line 56 and bent up and over the surface of opposite cover 27 and pressed against the top of member 53 to break it away along the weakened line 55 and thereafter move both members down into the resulting aperture 59 in the cover member. The horseshoe shape of the members 53 and 54 causes them to be engaged in interlocking relation in the aperture a in the cover. The apertures which are formed in the cover members by tearing or punching out the locking members 53 and 54 also permit observation of the contents of the two central pairs of cells in the carton.

The illustrated carton is adapted to accommodate two rows of six eggs each with the eggs aligned transversely. In order to permit the carton to be readily divided into two half-dozen containers, both side wall and cover forming portions H and [2 are formed at the longitudinal center with a transversely extending ridge formation 88 which is generally V-shaped and which extends across the cover member and partially down the adjacent side wall in the closed condition of the carton. A line of weakening indicated at 8i extends transversely of the bottom portion iii and side portions I l and I2 along the partition formations ll between the center pairs of cells It and through the apex of the ridge formations fill. The locking members 53 and 54, when in looking engagement in the aperture 59 in the cover member 26, hold the cover members firmly in closed relation for dividing the carton along the weakened line 8| by a breaking or tearing operation. The half-carton containers are held in closed condition by these locking members at one end and at the other end by the locking tabs 46 and 4! which engage in the end wall aperture 2!.

The eggs at the end of the half-cartons adjacent the dividing or tearing line El are retained in the half-cartons by the ridge formations Gil which form end wall sections.

In Fig. 8 there is illustrated a carton which is modified at the ends to provide an alternative form of locking means. The bottom portion is is provided with end walls ll having a central aperture '52 of generally rectangular shape and opening upwardly. The side wall and cover forming portions 13 and 74 are provided with end walls 75 and 16 which are formed without the longitudinally extending locking tabs which are provided in the form of carton previously described. The outer portions Ti and '18 of the end walls 15 and 16 are overlapped and secured by conventional fastening means such as staple '59. The upwardly opening aperture 12 permits the insertion of the stapling anvil into the carton in the space between the upper portions of the end pair of eggs for the application of the staple it without damage to the eggs.

A further modification of the carton is illus-- trated in Fig. 9 wherein the side wall and cover forming portions and 8| are formed with in tegral flap extensions 82 and 83. The carton is molded with flaps 82 and 83 arranged so that they are moved into upstanding abutting relation when the carton is closed whereby they may be secured together by adhesive, stitching, staples or other fastening means to retain the cover members in closed position.

. In the opened out position of all forms of the carton the side and cover forming portions extend laterally along opposite sides of the bottom forming portion, the walls being arranged so that in transverse section they have the general form of a spread-out letter W. In this condition the carton may be molded as a single integral member and readily removed from the mold. A plurality of the carton may be readily nested in the open condition for shipment, requiring a minimum of shipping space.

When the carton is filled and closed the side walls are positioned in substantially vertical planes. The filled cartons may be readily stacked in superimposed self-sustaining relation. When arranged in layers in a crate of standard size all available space in the crate is utilized due to the vertical side walls and adjacent cartons are subject to very little movement because their side walls are in abutting relation.

Due to the shape of the egg-receiving pockets or cells in the carton the eggs are supported in a tilted position at an angle displaced from the vertical. This permits the packaging of longer eggs in the carton than would be possible if the eggs were supported with the longer axis in vertical position. The length of the eggs which the carton will accommodate is not limited by the vertical dimension of the carton but by a diagonal dimension which is greater than the vertical dimension. When the filled cartons are packed in layers or tiers in a crate the tilted position of the eggs results in the eggs in the superimposed layers being misaligned with each other. Consequently the eggs in the lower layers are not required to directly support the eggs in the upper layers. The weight of the eggs above does not bear directly on the eggs below, and breakage is greatly reduced.

While specific details of construction and materials have been referred to in describing the illustrated forms of the carton, it will be understood that other details of construction and other materials may be resorted to within the spirit of the invention.

I claim:

1. A molded pulp egg carton, comprising, in the open position in which it is molded, a central bottom forming portion having a plurality of up wardly opening ovoid cells, and side wall and cover forming portions on opposite sides of said bottom forming portion, the end cells in said bottom forming portion defining end walls which terminate at the top in lateral downwardly and outwardly extending oblique abutment edges, and said side wall and cover forming portions having generally triangular end wall members connected at two sides to the respective side wall and cover forming members thereof and adapted. to engage along a third side in abutting relation with the top abutment dges of the bottom end walls when the side wall and cover forming portions of the carton are moved into closed position over the bottom portion thereof.

2. A molded pulp egg carton comprising a central bottom portion having a plurality of egg receiving cells therein which are separated along a longitudinal. medial lineby a. row'of spaced: upwardly extending pyramidal dividing members terminating in top abutment surfaces, the end cells of said bottom portion defining end walls which terminate in downwardly and outwardly diverging abutment edges, side. wall forming members hingedly connected. along. opposite edges of the bottom portion and extendingim a substantially vertical plane when. in the; closed position, integral cover forming. members. extending from the outer edges of the side wall forming members in a substantially horizontal plane insaid closed position, end wall forming members of generally triangular shape connected. along two sides to'the ends of the side wall. and cover forming members, a third sideofsaid end wall forming members being adapted to engage said abutment edges of the bottom end wallsand hingedly connected medial partition forming members extending downwardly from. said. cover forming members having their free edges in abutting relation with the abutment surfaceson the pyramidal dividing members.

3. A molded pulp egg carton comprising acentral bottom portion having a plurality. of egg receiving compartments therein which are separated along a medial line by a row of upwardly extending pyramidal dividing members terminating in generally horizontal abutment surfaces, the endcompartments of said bottom portion providing outer carton wall members which terminate at their upper edges in downwardly and outwardly extending oblique abutments, side wall members hingedly connected along opposite edges of the bottom portion and extending downwardly and outwardly thereof, integral cover forming members extending upwardly and outwardly from theedges of. the side wall. members whereby the carton walls form in transverse section which is taken between said egg receiving compartments. substantially the letter W, end wall members integrally connected along two sides with the ends of the sidewall and cover forming members, a third side of each of said end wall members forming an abutment edge for engagement in the closedposition with the end wall abutments on the bottom portion, and integral partition formingextensions on the outer edges of said cover forming members which are adapted to be folded into depending relation with said cover forming members tobring the free edges thereof in abutting relation with the abutment surfaces on the pyramidal dividing members in the closed position.

4.. A. molded. pulpegg carton having a cellular bottom portion and side wall; and cover forming portions which are integrally joined in. laterally extending relation to said bottom portion when the carton is. in an opened out condition with the longitudinal walls of the carton having in transverse cross section taken between the cells thereof substantially the form of the letter W, end walls on said bottom portion having a. central aperture therein, end walls on said. side wall and cover forming portions having portions which are moved into overlapping relation above the endwalls of said bottom portion when the carton is closed, and integral locking tabs xtending from said overlapping end wall portions which are bendable into interlocking engagement in the apertures in the bottom end walls.

5. A molded egg carton having a cellular bottom portion .andside wall andcover forming portionswhich are-integrally joined: in'laterally extending relation to said bottom portion when All the carton. is in an opened out condition with the longitudinal walls of the carton having in transverse cross section taken between the cells thereof substantially the form of the letter W, end walls on' said bottom portion having a. central aperture therein, end walls on. said side wall and cover forming portions having portions which are moved into overlapping relation above the end walls of said bottom portion when the carton is closed, and integral locking tabs on the outer. edgesof said. overlapping end wall portions which arebendable. into. overlapping relation and into interlocking engagement. in the. apertures in the. bottom end. walls.

6. A molded pulpegg carton comprising a central bottom portion having a plurality of egg. receiving cells. therein which are separated along a longitudinal central line. bya row. of upwardly extending pyramidal dividing members terminating in horizontal top abutment surfaces, the end cellsof said bottom portion defining end walls which. extend upwardly and terminate in downwardly and outwardly extending oblique abutment edges, side wall forming members hingedly' connected along, opposite edges of the bottom portion and extending in a. substantially vertical plane when in the closed position; integral cover forming wall members extending from the topedges of the-sidewall forming members in a substantially horizontal plane, end wall members of generally triangular shape integrally connected along two sideswith the ends 01 the side and cover forming. wall members, the third side or said end wall-members being adapted to engage said oblique abutment edges on the bottom end walls, and hingedly connected partition forming members extending downwardly from said cover forming wallmembers with their free edges abutting the horizontal top surfaces on the pyramidal dividing members.

'7. A molded pulp egg carton, comprising, in the open position in which it is molded, a central bottom forming portion having a plurality of upwardly opening egg receiving cells, and side wall and'cover for-ming'portions on opposite sides of said bottom forming portion, the end cells in said bottom forming portion defining bottom end walls which terminate at the top in lateral diverging downwardly and outwardly extending abutment forming edges, and said side wall and cover forming portions having members extending between and connecting the ends of the respective side wall and cover members thereof which members form top endwalls, said top end walls having edges arranged-to engage in abutting relation with the top abutment edges of the bottom end walls when the side wall and cover forming portions of the carton are folded into closed positio over the bottom forming portion thereof.

8. A molded pulp egg carton comprising a central bottom portion having a plurality of egg receiving cells therein which are separated along a longitudinal medial line by a row of spaced upwardly extending pyramidal dividing members terminating in top abutment surfaces, the end cells of said bottom portion having outer walls forming bottom end walls, said bottom end walls having the top edges thereof extending laterally and inclined outwardly and downwardly, side wall forming members hingedly connected along opposite edges of." the bottom portion and extending in. a substantially vertical plane when in the closed position, integral cover forming members extending from the outer edges of the side wall forming members in a substantially horizontal plane in said closed position, and end members connected along two side edges of the ends of the side wall and cover forming members and having the edges along a third side positioned in abutting relation with the inclined top edges of said bottom end walls when in the closed position.

9. A molded pulp egg carton, comprising, in the open position in which it is molded, a central bottom forming portion having a plurality of upwardly opening egg receiving cells, and angularly-related side wall and cover forming members connected by hinge forming portions to opposite sides of said bottom forming portion, the end cells in said bottom forming portion having bottom end walls which terminate at the top in downwardly and outwardly diverging lateral edges, said side wall and cover forming members having top end wall forming members connecting adjacent ends of the respective side walls and cover members thereof, said top end wall forming members extending less than the full width of the bottom forming portion and having inner portions thereof extending in partial overlapping relation to each other above the top edges of the bottom end walls when the side wall and cover forming members of the carton are hinged into closed position over the bottom forming portion thereof and means for securing said top end wall portions in said overlapping relation.

10. A molded pulp egg carton having a cellular bottom portion and side wall and cover forming portions which are integrally joined in laterally extending relation to said bottom portion when the carton is in an opened out condition, the longitudinal walls of the carton being arranged when in the opened out condition to provide in transverse section taken between the cells thereof substantially the form of the letter W, bottom end walls on said bottom portion, top end walls on said side wall and cover forming portions, said top end walls extending less than the full width of said bottom portion and having free marginal portions which are moved into overlapping relation in the plane of said top end walls above the bottom end walls when the carton is closed, and fastening means for securing said overlapping marginal end wall portions together.

11. A molded pulp egg carton having a cellular bottom portion and side wall and cover forming portions which are integrally joined in laterally extending relation to said bottom portion when the carton is in an opened out condition with the longitudinal walls of the carton having in transverse cross section taken between the cells thereof substantially the form of the letter W, bottom end walls on said bottom portion having an upwardly opening central aperture therein and top end walls on said side wall and cover forming portions which are moved into upwardly extending generally vertical relation above the bottom end walls when the carton is closed, said top end walls extending less than the full width of the bottom forming portion and having free marginal portions which overlap in the vertical plane above said aperture in the bottom end walls and which receive a staple member for securing said portions together in the closed position.

12. A molded pulp egg carton comprising a central bottom portion having a plurality of egg receiving cells therein which are separated along a longitudinal medial line by a row of spaced upwardly extending pyramidal dividing members terminating in top abutment surfaces, the end cells of said bottom portion having outer walls forming bottom end walls which terminate at the top in laterally diverging downwardly and outwardly extending abutment forming edges, side wall forming members hingedly connected along opposite edges of the bottom portion and extending in a substantially vertical plane when in the closed position, integral cover forming members extending from the outer edges of the side wall forming members in a substantially horizontal plane in said closed position, top end wall forming members connected to the ends of the respective side wall and cover forming members, said top end wall forming members having edges arranged to engage in abutting relation with the top abutment edges of the bottom end walls and hingedly connected medial partition forming members extending downwardly from said cover forming members having their free longitudinal edges in juxtaposed relation to the abutment surfaces on the pyramidal dividing members, the ends of said partition forming members being spaced from said end wall forming members, said side wall and cover forming members having transverse inwardly extending partition formations which are V-shaped in cross section and arranged centrally of longitudinally adjoining cell formations, the apex thereof defining a dividing line for separating the carton into two sections by tearing along said line.

13. A molded pulp egg carton comprising a central bottom portion having parallel rows of egg receiving cell formations therein, said bottom portion having end walls which extend upwardly and terminate in lateral downwardly and outwardly extending oblique abutment edges, side wall forming members hingedly connected along opposite edges of the bottom portion and extending in a substantially vertical plane when in the closed position, integral cover forming wall members extending from the top edges of the side wall forming members in a substantially horizontal plane, generally triangular end wall members integrally connected at two sides with the ends of the side and cover forming wall members, said end wall members being moved to bring the third side thereof into engagement with said abutment edges on the bottom end walls and flap forming members extending upwardly from the free edges of said cover forming walls in abutting relation and adapted to be secured together to hold said cover forming wall members in closed position.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,822,936 Reichel Sept. 15, 1931 2,088,603 Kronenberger Aug. 3, 1937 2,423,756 Chaplin July 8, 1947 2,446,264 Cox Aug. 3, 1948 2,455,295 Cox Nov. 30, 1948 2,466,579 Cox Apr. 5, 1949 2,529,140 Cox Nov. 7, 1950 2,569,681 Lennon Oct. 2, 1951 FOREIGN PATENTS Number Country Date 748,732 France Dec. 20, 1932 

